Test Benches are mandatory for the execution of Hardware-in-the-Loop (HiL) tests, in which the real hardware (electronic control units) can be integrated for the purpose of test automation. This usually requires both the automated control of all components and the simulation or integration of other electronic components.

Complexity of Modern Test Bench Systems. Since the most complex algorithms, from driver assistance systems to highly networked vehicle functions, are traditionally to be tested on a hardware-in-the-loop system, very high demands are placed on the underlying hardware. For example, the hardware of a HiL system must be precisely matched to the requirements of the respective test scope as well as to the technical conditions of the electronic components to be tested.

Real-time requirements for HiL systems. Modern vehicle functions sometimes have to perform critical calculations and safety-relevant actions in the millisecond or even nano-second range. Thus, complex real-time requirements sometimes apply, which must also be met by the test bench hardware. However, not all functional requirements require complex real-time conditions, so that testing can often also be carried out with significantly simplified and therefore less expensive hardware structures. However, the technical analysis of the underlying hardware requirements for a specific test project requires many years of domain-specific experience.

Networking Requirements at the HiL Test Bench. Today's driver assistance systems as well as generally modern algorithms in the vehicle are implemented as highly distributed systems, mostly based on the AUTOSAR framework. For example, the correct functioning of an individual vehicle function sometimes requires the correct behavior of a dozen other communication participants or other control units. In the context of so-called residual bus simulations, the communication behavior of partner ECUs can sometimes be simulated under real-time conditions at the HiL test station. Alternatively, partner control units can also be integrated into the existing simulation as real hardware by connecting real vehicle buses. In this case we speak of networked HiL systems, which in extreme cases can even be used to simulate a complete vehicle.

Test Automation Systems on the HiL Test Bench. What is also essential for a modern HiL system is the ability to control all hardware and electronic components (such as resistance simulations, relays, sensors or actuators) in a reproducible and automated manner at all times. As a rule, very complex and powerful test automation systems are used for this.

Professional Conception of HiL Test Benches. Our Test Automation experts will be happy to support you from the first requirement analysis of your HiL system to the commissioning of the test bench and the implementation and automation of your test scope. Benefit from our knowledge of modern automation systems on the HiL test bench and from our experience in the areas of test conception as well as test methodologies and test management.